Method of making a continuous strand sheet molding compound

ABSTRACT

An improved sheet molding compound is provided having a greatly increased tensile strength in the direction of its longitudinal axis. The tensile strength increase results from the inclusion of a number of continuous glass fiber rovings. There is also disclosed a method for making the sheet molding compound and incorporating the continuous rovings between the top and bottom layers of resinous material. As part of the process, an improved doctor blade is provided which has a plurality of holes through which the continuous rovings are pulled after passing through a bath of the resinous material, thus causing the roving to be thoroughly impregnated with the resin.

United States Patent Meyer et a1. Aug. 5, 1975 [541 METHOD OF MAKING A CONTINUOUS 3,689,343 9/1972 Eisner 156/179 STRAND SHEET MOLDING COMPOUND 3,718,527 2/1973 Goodman 156/180 3,738,895 6/1973 Paymal 156/622 {751 In ent rs: Raymond W. Meyer. T llm g 3,769,115 10/1973 Rasmussen et a1. 156/622 Francis R. McGranaghan, Stow; 3,822,159 7/1974 Lee et a1. 156/178 Dale K. Evans, Akron, all of Ohio 3,823,049 7/1974 Vetrovec 156/436 3,840,384 10/1974 Reade et a1... 156/180 1 1 Asslsnfiei The General Tire & Rubber 3,844,864 10/1974 Glover et al, 161/143 Company, Akron, Ohio I22] Filed: Aug 8' 974 Primary ExaminerWilliam A. Powell Assistant E.tuminer.lerome W. Massie 121 Appl. No: 495.595

Related US. Application Data 1571 ABSTRACT (63] Continuation of Ser. No, 287,186, Sept. 7, 1972. An improved Sheet molding Compound is provided abandoned having a greatly increased tensile strength in the direction of its longitudinal axis. The tensile strength in- [52] [1.8. CI. 156/624; 118/125; 156/179; crease results from the inclusion of a number of con- 156/256; 156/436; 156/441; 428/294; 428/303 tinuous glass fiber rovings. There is also disclosed -a 151 1 I111. c1. B328 17/04 method for making the Sheet molding Compound and [5 Field 0 Search 15 22 2 4 7 179 incorporating the continuous rovings between the top 5 27 1 0 43 441 176 256; 1 1/143 and bottom layers of resinous material. As part of the 170, 176; 118/125, 103, 405 process, an improved doctor blade is provided which has a plurality of holes through which the continuous 5 References Cited rovings are pulled after passing through a bath of the UNITED STATES PATENTS resinous material, thus causing the roving to be thoroughly impregnated with the resin. 3,163,689 12/1964 lves 156/179 3,674,620 7/1972 McCarthy et a1 156/179 6 Claims, 7 Drawing Figures )f/ I; a

- 2 2a =.,-e% W PATENTED 51975 3,898, 1 l3 SHFU 1 [1F 3 METHOD OF MAKING A CONTINUOUS STRAND SHEET MOLDING COMPOUND This is a continuation of application Ser. No. 287.186, filed Sept. 7, I972, now abandoned. U.S. Pat. No. 3,847,707 has issued from application Ser. No. 45I,637. filed Mar. I5, I974, which was a division of application Ser. No. 287,l86.

BACKGROUND OF THE INVENTION This invention relates to sheet molding compounds (SMC). and more particularly, to an SMC having con tinuous fibrous rovings and a substantially greater tensile strength in the direction in which the rovings are oriented.

Conventionally. SMC has been made by spreading a layer of resinous material. such as a polymeric resin, on a pair of plastic carrier sheets. then cutting a number of glass rovings into short strands and sprinkling the strands randomly on the bottom layer of resin just before the top layer of resin is joined thereto by means of a pair of rollers. The tensile strength of the resulting compound is uniform. i.e.. approximately the same in all directions because of the random distribution of the reinforcing glass fibers.

The SMC would then normally be press-formed with matched-metal molds. It was found. however, that for many applications of the SMC the molded part would have weak points. frequently at a juncture where the charges of the compound would flow together during the press-forming. An example would be the forming of a rectangular box. such as a material handling tray, wherein the corners of the box would be weak and would tend to crack easily because of the way in which the SMC charges would flow together to form the corner.

In an attempt to make a stronger part, the prior art tried several solutions in which the strength of continuous glass rovings was utilized. In one attempt, continuous rovings were wound on a drum to form the reinforcement. and a cut was then made longitudinally, i.e., parallel to the axis of the drum. so that the reinforcement could be removed from the drum. While this method resulted in a stronger part when molded, an obvious limitation was that the part could be no longer than the circumference of the drum on which it was formed. In addition. unless the rovings were wound very tightly on the drum, they would tend to move Iatcrally which resulted in gaps between the rovings and hence. weak spots in the molded part.

In an attempt to overcome the problems mentioned above. the prior art then prepared reinforcements by weaving the fiber glass rovings. While the woven reinforcing mat prevented the rovings from moving laterally. the weaving ofthe rovings was quite expensive and the individual rovings tended to be insufficiently wetout. ie. the rovings could not be as completely impregnated with the resin as is necessary to get maximum tensile strength from the roving. Unless the individual glass fibers in each roving are separated from each other by the resin. they will rub together, abrade and weaken. thus reducing the total strength of the roving.

Therefore. in accordance with a primary aspect of the present invention. an improved sheet molding compound is provided which has a substantially higher tensile strength along its longitudinal axis. The compound comprises top and bottom layers of a resinous material and a plurality of fibrous rovings impregnated with resinous material and positioned between the top and bottom layers. The rovings are oriented to extend longitudinally of the sheet molding compound. thereby greatly increasing the tensile strength of the compound in that direction.

In accordance with another aspect of the present invention a method of making the improved continuous strand sheet molding compound is provided. The method involves the steps of:

a. providing a doctor blade having a plurality of selectively spaced orifices extending therethrough;

b. spreading a layer of resinous material on the carrier sheets;

c. continually pulling each of the continuous rovings through a bath of resinous material. then through one of the orifices of the doctor blade to impregnate the roving with the resin; and,

d. pressing the carrier sheets and layers of resin together with each of the rovings positioned between the layers of resin and extending longitudinally.

In accordance with a further aspect of the present invention an improved doctor blade is provided which is especially suited for use in making a continuous strand sheet molding compound and for practicing the method of making it. The doctor blade comprises an elongated blade member having end portions adapted to be fixedly mounted and including means for spreading a generally uniform layer of resinous material on a moving substrate. In addition. the blade member has at least one orifice having a longidudinal axis. The orifice is through the blade member so that a continuous bundle of fibers comprising a roving can be pulled through after having passed through a bath of resinous material. The orifice insures that the ratio of resinous material to fiber will be uniform throughout the length of each rov ing.

Accordingly, it is a primary object of the present invention to provide a sheet molding compound having a greatly increased tensile strength in the direction of it longitudinal axis.

It is also an object of this invention to provide a sheet molding compound which can be continuously produced without the necessity of expensive manual oper ations or complicated equipment such as is needed to weave rovings.

It is a further object of the present invention to provide a method for continuously producing the improved sheet molding compound and to provide an improved doctor blade for use in uniformly impregnating the continuous rovings.

These and other objects and advantages of the invention will become apparent from the following description when read in conjunction with the accompanying drawings wherein:

BRIEF DESCRIPTION OF THE DRAWINGS FIG. I is a perspective of a sheet molding compound machine or impregnator that is used to make SMC in accordance with the method of the present invention.

FIG. 2 is a cross-section taken on line 22 of FIG. 1;

FIG. 3 is a fragmentary cross-section taken on line 33 of FIG. I and FIG. 2;

FIG. 4 is a cross-section ofthe doctor blade taken on line 44 of FIG. 3;

FIG. 5 is a front elevation of the improved doctor blade;

FIG. 6 is another cross-section of doctor blade taken on line 6-6 of FIG. 5; and

FIG. 7 is a fragmentary perspective of the improved sheet molding compound of the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT Referring now to the drawings which are for the purpose of illustrating preferred improvements of the present invention and not for the purpose of limiting the same. FIG. 7 shows the improved sheet molding compound ]0 as it comes off the impregnator. The sheet molding compound 10 includes a plurality of continuous bundles 12' of fibrous rovings spaced apart in a mass of hardenable resinous material M. The compound is formed between a pair of carrier sheets l6a and I6!) which can be made of any thin flexible material such as polyethylene plastic sheet.

FIG. I shows a conventional sheet molding compound impregnator which has been modified by the substitution of the improved doctor blade 22. In the conventional process for making sheet molding compound, the pair of carrier sheets 16a and 16b are in the position shown in FIGS. I and 2 and each are coated with a thin. uniform layer of the resinous material 14 by a pair of blades such as the conventional doctor blade 30. In the method of the present invention the conventional doctor blade is used only to coat the top carrier sheet 160. and the bottom carrier sheet 16b is coated by the improved doctor blade 22. The improved doctor blade can be held rigidly by any of the means commonly used to mount the conventional doc tor blade. such as the holding blocks 32. Restraining means, such as wall members 33, should be employed to make it possible to keep a substantial mass of resin 14 in place behind the doctor blade.

As best can be seen in FIG. 6, the doctor blade 22 is an elongated member shown as having opposing flat surfaces 24 and 26 and a narrow bottom surface 27 which serves the purpose of spreading the resinous material 14 in a thin layer. The surface 27 is shown as being about one-sixteenth inch wide and extending the length of the blade 22. The surface 27 is further illustrated as being planar. but it should be understood that surface 27 may be of a different configuration for special applications. The doctor blade also includes a plurality of orifices which, in the preferred embodiment. comprise a cylindrical portion 28 and an incoming tapered portion 29, the function of which will be described in more detail subsequently.

Referring again to FIGS. 1 and 2. the rovings 12 are shown coming from their storage locations. and being guided through the holes in the first guide bar 34 and maintained in a generally horizontal orientation by the second guide bar 36. It is desirable that the rovings 12 enter the bath of resin [4 in a nearly horizontal position to minimize the drag and so that. after being pulled through the tapered portion 29 and cylindrical portion 28 of the doctor blade, the rovings will be uniformly impregnated with the resin. After passing through the doctor blade. the impregnated rovings I2 then are positioned between the coated carrier sheets 16a. I6!) and the composite of the carrier sheets. layers of resin and impregnated rovings are pressed together by the pair of rollers 38.

The improved sheet molding compound of the present invention provides for the first time an SMC which takes full advantage of the greater tensile strength of the fiber materials used to reinforce such compounds. The fibrous rovings may be selected from a variety of fiber material, however. glass fiber rovings are preferred for most applications because of the extremely high tensile strength of the individual glass fiber. typically in the range of 500,000 to 750,000 p.s.i. The glass fibers are also compatible with any of the commonly used resinous material and are generally considered chemically inert. It is within the scope of the present invention. however. to use other fiber material for the rovings. such as sisal and hemp fibers, as well as asbes tos. graphite. boron. and other metal fibers. Another group of materials commonly used for rovings include the fibers of wool. cotton. polyester and nylon. The rovings are preferably made from a plurality of the continuous fibers, primarily because of the safety feature provided by having a large number of fibers. so that if one breaks. the load is simply transferred to the remaining fibers in the bundle. In the preferred embodiment of the present invention. the rovings comprise bundles of at least about 25 continuous glass fibers and preferably as many as 50 separate fibers. It has been discovered that by the use of continuous bundles of fi bers rather than the randomly distributed short strands of the prior art. the longitudinal tensile strength of the resulting SMC can be increased to as much as twice that of the conventional SMC. If the part to be pressformed from the SMC requires greater tensile strength in more than just one direction. it is possible to place one charge of the continuous strand SMC on top of another. in the match-metal mold, with the plurality of charges of SMC oriented at angles to each other. i.e.. with the continuous rovings of the charges oriented at different angles. It can be readily appreciated that the SMC of the present invention thereby affords a greater degree of freedom in the design of parts to be made from SMC.

The proportion of fiber rovings to resin mixture can vary greatly with only a small number of continuous rovings being used if only a small increase in longitudinal tensile strength is needed. It was found. however. that an SMC having about 50 p.b.w. (parts by weight) of continuous fibrous rovings and about 50 p.b.w. of resinous mixture yields optimum results in terms of maximum tensile strength without a failure to properly impregnate and protect the rovings. Nearly optimum results can be achieved by keeping both the rovings and the resinous mixture within a range of 40-60 p.b.w.

The importance of the improved doctor blade can be readily appreciated if the necessity for properly impregnating the rovings is understood. As can best be seen in FIG. 4. as the individual rovings l2 proceed through the bath of resin 14, and then through the doctor blade. some of the resinous material is pulled into the tapered portion 29. This excess resin is then wiped off the moving roving as it proceeds through cylindrical portion 28. The most important part of the impregnating step is to provide a means whereby the resin is forced in among the individual fibers of the roving. so that the resin serves to separate the individual fibers from each other. thus preventing them from abrading each other and eventually breaking. In the past it has been difficult to impregnate continuous rovings with heavily filled mixes sufficiently to obtain the maximum benefit from the greater strength inherent in a continu ous roving. The doctor blade of the present invention now makes it feasible to simultaneously and continuously impregnate any desired number of rovings up to 50 or more.

In the preferred embodiment of the doctor blade. the orifices are arranged in 4 parallel rows. each row horixontally off-set or staggered from the adjacent rows. After the impregnated rovings are pulled through the doctor blade. however. they do not remain in the multilayer arrangement, but are all within one layer. The in dividual orifices are made by drilling a hole starting at surface 24 perpendicularly through the blade. thus creating cylindrical portion 28. Next. tapered portion 29 is made by counterboring or milling to give an included angle of approximately 50. A typical diameter for cylindrical portion 28 would be approximately 0.090 inch. which is just slightly larger than the diameter of the roving before impregnation. in the subject embodiment. the orifices in each row are on a center-to-center separation of about seven-eighths of an inch and the adjacent rows are separated horizontally by about three-eighths of an inch. it will be readily apparent that the configuration of the doctor blade or its dimensions could vary significantly from those just described and still be within the scope of the present invention, as long as the doctor blade and its orifices serve the dual function of aligning the rovings and uniformly impregnating each of the rovings over its entire length.

The resinous material used in making the sheet molding compound of the present invention can be selected from any of those used in making a conventional SMC. Typical resins used would include polyester. phenolic. epoxy. silicone, alkyd. acrylic and polyethylene. However. the thermosetting resins are predominantly used. and the thermoset used most frequently in applications requiring greater tensile strength in continuous strand SMC are the polyester resins. For some applications it may be desirable to use a thermosetting resin such as polyester as the base material and include a thermoplastic resin to improve the surface finish. In making the SMC. whether the conventional or the continuous strand. it is desirable to include in the resinous mixture a thickener, such as a Group II metal oxide. preferably magnesium oxide or calcium oxide. In the preferred embodiment (50 p.b.w. resin mixture and 50 p.b.w. rovings) the resin mixture contained H0 parts of filler to 100 parts of the polyester resin. If the p.b.w. of the glass rovings is increased. the proportion of filler in the resin mixture should be reduced proportionately so as not to reduce too greatly the overall p.b.w. of the polyester or other resin.

in converting the conventional impregnator for making sheet molding compounds to one for the continuous strand SMC. the modified doctor blade should normally be put at a lower setting. i.e.. closer to the carrier sheet. than a conventional doctor blade. since resin mix is also being added to the composite by means of the impregnated rovings. Therefore. the lower doctor blade setting will yield a thinner layer of resin mix on the bottom carrier sheet and the end result will be an SMC having the same proportions of fiber reinforcement and resin mix as in the conventional SMC. A typical adjustment on the setting of the modified doctor blade would be approximately .OlO of an inch below the conventional setting which has normally been in the range of 0.040 to 0.060 inch.

A modification of the SMC which improves the tensile strength of the resulting material in a direction transverse to the orientation of the continuous rovings can be accomplished by diverting one or more of the continuous impregnated rovings to a chopping station located down-stream from the modified doctor blade. for example. The chopping of the resin impregnated roving into short strands can be done in the same manner as is done for making the conventional SMC The short strands, generally about one to two inches long. are than allowed to fall randomly on the combination of the bottom layer of resin and the impregnated continous rovings. just before the top layer of resin is combined therewith. and pressed into a sheet. For the optimum results described previously in conjunction with the preferred embodiment. where the SMC had 50 p.b.w. rovings, the proportion of the shorter strands to the continuous strands should not exceed about 30 percent.

It will be understood by those familiar with the art that many modifications and alternatives can be made in the apparatus. method and material of the present invention. Accordingly. it is intended that the foregoing specification embrace all such alternatives and modifications as fall within the spirit of the appended claims.

What is claimed is:

l. The method of continuously making a fiber rein forced sheet molding compound having superior molding qualities when press-formed in a matched-metal mold comprising the steps of:

a. spreading a top layer of resinous material under a conventional doctor blade on one side of a moving flexible top carrier sheet,

b. spreading a bottom layer of resinous material under an improved doctor blade on one side of a moving flexible bottom carrier sheet.

c. passing a plurality of fibrous rovings through a mass of resinous material.

1. the axes of said fibrous rovings being selectively spaced transversely apart through selected horizontally spaced openings defined by a guide bar across said carrier sheets.

2. each ofsaid fibrous rovings comprising a loose bundle of individual fibers. and

3. each of said fibers being individually coated with said resinous material within said mass of resin ous material.

d. respectively compressing together each said bundle of said fibrous rovings passing from said bath through selected horizontally spaced and sized orifices defined through said improved doctor blade to remove excess resinous material and to uniformly impregnate each of said compressed rovings with said resinous material.

c. passing said fibrous rovings from said orifices as horizontally spaced onto said bottom layer of resinous material as spread on said bottom carrier sheet.

. compressing said top carrier sheet toward said bot tom carrier sheet to force said top layer of resinous material and said bottom layer of resinous material together to consolidate said top layer of resinous material. said fibrous rovings and said bottom layer of resinous material into a composite sheet molding compound.

2. The additional steps following step d) of claim 1 including prise glass fibers.

4. The method of claim 2 wherein said fibrous rov irigs comprise from about 10 p.b.w. to about 30 p.b.w. of said short strands of fiber.

5. The method of claim 1 wherein said resinous mate rial includes a metal oxide thickener.

6. The method of claim 2 wherein said short strands of fiber are less than about 2 inches in length. 

1. THE AXES OF SAID FIBROUS ROVINGS BEING SELECTIVELY SPACED TRANSVERSELY APART THROUGH SELECTED HORIZONTALLY SPACED OPENINGS DEFINED BY A GUIDE BAR ACROSS SAID CARRIER SHEETS,
 1. THE METHOD OF CONTINUOUSLY MAKING A FIBER REINFORCED SHEET MOLDING COMPOUND HAVING SUPERIOR MOLDING QUALITIES WHEN PRESS-FORMED IN A MATCHED-METAL MOLD COMPRISING THE STEPS OF: A. SPREADING A TOP LAYER OF RESINOUS MATERIAL UNDER A CONVENTIONAL DOCTOR BLADE ON ONE SIDE OF A MOVING FLEXIBLE TOP CARRIER SHEET, B. SPREADING A BOTTOM LAYER OF RESINOUS MATERIAL UNDER AN IMPROVED DOCTOR BLADE ON ONE SIDE OF A MOVING FLEXIBLE BOTTOM CARRIER SHEET, C. PASSING A PLURALITY OF FIBROUS ROVINGS THROUGH A MASS OF RESINOUS MATERIAL,
 2. EACH OF SAID FIBROUS ROVINGS COMPRISING A LOOSE BUNDLE OF INDIVIDUAL FIBERS, AND
 2. The additional steps following step d) of claim 1 including i. cutting into short strands a diverted portion of said fibrous rovings passing from said improved doctor blade; and ii. randomly dropping said short strands of said fibrous rovings as impregnated onto said bottom layer of resinous material as spread on said bottom carrier sheet to thereby include said short strands with said fibrous rovings as disposed by step e).
 2. each of said fibrous rovings comprising a loose bundle of individual fibers, and
 3. each of said fibers being individually coated with said resinous material within said mass of resinous material, d. respectively compressing together each said bundle of said fibrous rovings passing from said bath through selected horizontally spaced and sized orifices defined through said improved doctor blade to remove excess resinous material and to uniformly impregnate each of said compressed rovings with said resinous material, e. passing said fibrous rovings from said orifices as horizontally spaced onto said bottom layer of resinous material as spread on said bottom carrier sheet, f. compressing said top carrier sheet toward said bottom carrier sheet to force said top layer of resinous material and said bottom layer of resinous material together to consolidate said top layer of resinous material, said fibrous rovings and said bottom layer of resinous material into a composite sheet molding compound.
 3. The method of claim 1 wherein said fibers comprise glass fibers.
 3. EACH OF FIBERS BEING INDIVIDUALLY COATED WITH SAID RESINOUS MATERIAL WITHIN SAID MASS OF RESINOUS MATERIAL, D. RESPECTIVELY COMPRESSING TOGETHER EACH SAID BUNDLE
 4. The method of claim 2 wherein said fibrous rovings comprise from about 10 p.b.w. to about 30 p.b.w. of said short strands of fiber.
 5. The method of claim 1 wherein said resinous material includes a metal oxide thickener.
 6. The method of claim 2 wherein said short strands of fiber are less than about 2 inches in length. 